Conductor



CONDUCTOR Filed March 25, 1925 m hw www uw Patented Nov. 11, 1.930

UNITED STATES lPMENT OFFICE WILLIAM B. TEN EYCK, DECEASEILBY CI-IRSTENE Z. TEN EYCK, ADMINISTRATRIX-,OF MONTCLAIR, NEW JERSEY, ASSIGNOB, BY MESNE ASSIGNMENTS, TO `'WTE-STERN ELECTRIC COMPANY, INCORPORATED, A CORPORATION -OF NEW YORK` CONDUCTOR Application filed March 25, 1925. serial Nq. 18,333.

This invention relates to conductors for the transmission of electrical energy and more particularly to a method of constructing a signaling conductor having an external layer of a material of high permeability for the purpose of increasing the inductance of the conductor.

One manner of increasing the inductance of a conductor employed for the transmission of alternating current is to wrap the conductor spirally with a layer of wire `or tape of magnetic material. This method. is known in the art as vcontinuous inductive loading as distinguished from lump loading by means of inductance coils distributed at intervals along the conductor. Until recently iron has been considered to be thefonly material suitable for continuous loading but it has nowbeen discovered that a more suitable material may be procured in the form of an alloy ofv nickel and iron. When these two metals are combined in the proper proportions andthe resulting alloy 1s given a properheat treatment, a material having a very high permeability at low magnetizing forces is obtained. Y

One form of this material which has been used in a submarine cable comprises TS1/2% nickel and 21A/2% iron. Alloys of nickel and iron having similar characteristics, especially high permeability at low magnetizing forces, have been entitled permalloys. Other properties possessed by these alloys which increase their value as a loading material are a hysteresis losslower than that of iron and a high resistivity, both properties being conducive to increasing the efficiency of the cable by lowering the eective resistance of the conductor. When it was attempted to employ this material in the form of a tape for continuous loading, diculties were encountered. It was found that if the permalloy tapel was first heated and then cooled before applying to the conductor, internal stresses were set up upon bending of the tape, causing the permeability to be very materially lowered. This difficulty was overcome by applying the tape to the conductor before giving the tape the heat treatment and then subjecting the taped conductor to the heating and cooling necessary to produce high permeability in the loading material.

Further ditliculty, however, was experienced in that the permeability of the loa'ding material was lowered by what appeared to be adhesion between the copper conductor and the loading tape. It is believed that this adhesion occurs when the taped conductor is subjected to the high temperatures'necessary for the proper'heat treatment and that upon subsequent cooling the tape is subjected o stresses-which cause a lowering of its permeability.

ln the construction of a loaded conductor it has been the practice to wrap a layer of magnetic material, comprising a nickel-iron alloy, closely around the conductor consisting of a central copper wire surrounded by six flatv copper strands, the whole making a compact structure with very little space not 'occupied by metal. To give the loading material the desired magnetic characteristics, this conductor was heated to approximately 8500` C. and then cooled at apreferred rate. On' heating, both metals expand but the copper, becauseof its higher'temperature cocincient, expandsmore than the loading materialV with the result that it presses tightly against the loading material when the conductor is at the high'temperature and if the structure is a fairlytight one, the magnetic tape is stretched, an elongation of as much as 1% having been observed.V This stretching has apparently no directetfect on the magnetic properties since it occurs ata temperature above the magnetic transformation point but it does show effects of high pressure between the metals. At the temperature of 850 C. both metals are relatively soft and since they are forced together by thermal expansion there is a tendency for the loading material to weldto the copper, the extent to which the metals are welded depending on several factors such as the tightness of the copper structure and the character Vof the` In this connection it has metal surfaces. been noted that although the loading material Awelds to the copper,`welding of the copperV strands to the central wire has very rarely been observed and no weldinghas been ob- AinL permeability over Wide 4 range. in* points served betweenlayers or the loading material `Whenvinore than Vone layer has been used. These yresults suggest that' Welding is pos` L sibly nota simplecase or fusion, or the tivo l considerable magnitude producing ai 'strain metalsjbu't some effectbrought-aboutby cheniical action.

,the copper and parts or it arefbent, stretched or compressed depending uponV the p articular ac idental conditions ,Oi adherence. y Even thong the forces involved may be very small,

thefstress'es atpoints in the tape may be of s'it to' reduce the permeability at Spots to af veryV :small fractionoffthat which the tape .ivoiildliave had if'not subjected tofs'uch l V.sti-ain. fTlie resultantconductor, therefor@ is forni tinductance measured `from'foot f to foot isfloaded With alinaterial Which varies sdpdidid by d fraction of ad inch;

y The copper tapes upon being stranded about the central conductor do not present a true cylindrical surr'alcesince the'edges or the tape dof not lie in close Contact with they-centralr conductorbut present spirallededges.

As the cooling proceeds; therefore,a sticking Vor yWelding of the material may .occur atvaii- Aours 4points along these edges and vthe subsequent contraction of the copper set up stresses in the alloy tape. p

""iDur'ng the` cooling `portion ofk the heat treatment theijalloytape cool more .rap- 4.0Y

idly at first than does the copper. conductor due1 to its intimate coiitactfivitlithe cooling y l medium so'that the. alloy tape quickly. comes finto intimat'econtact yyvitlithe copperv strands. i-lWhateverma-yfbe the truepexplanation for the difficultyexperiencedgit has largely been 'overcome by 'providing a small air space betweenfthe layer or loading vmaterial. and the signaling `'conductor.ivi/'hen the loading mate- 5' ndi is'dppiied. This, method @remaining V50 high permeability .is described aty length in Vpatenty to G. vVV-lillmem No. 1,586,887, granted Y June 1,1926. f

vvound in position, the desired result may be fobtained by placing allayer or paper upon vthe rconductor before the'loading material is Wound thereon. This layer lofpapeiis burned outduring the 'subsequent heat treatment thus Y giving the desired spacing between the loady ing material ,a'nd the conductor. This method described in detail in patentv to B.` Ten Y Eyck, No. 1.5865862', granted June 1, i926.

Masai-,fais preeminent@ is t@ prdvideidfihd pida-adi adding di agadiing conductor With magenticmaterial Which requires heat treatment to develop its'niaximum permeability and Whose characteristics are subject to undesired change under appliedstressesiV o l if Another object' of the 'invention is to prov-9 "videacmethodor applying/magnetic loading material to-an electrical conductorand"y subjecting it to heat- Vtreatment inn-such a deleterious stresses.

ma-nner asyto [prevent ther setting 'pup or"V contemplates the method of applying a load- Aing "material to"` an electrical conductor' in which the loading material and conductor spacdjapart during theheat treatment soy 'to' avoid `obtaiiiing lovvorfvariable values lof'permeability. This invention is in vclosedfin thefab'ov'e mentionedpatents to G.

HW. Elnienpand Wi BfTe'n Eyck.; Each of these inventions has' certain advantages over f drawing in yvhich Fig. lis a. plan'vieW shoi'rv-VK onefmjethod of' 'carrying lout the'in'vention, and Fig. 2 is a. vieWI'of, ay loaded conductor prepared in accordance Withthe fea'- 4 i;l''vs or the'inventio'iip 5 'f I To accomplish thesejobjects the invention thelnatur'eoranalternative tol those dis- "85 A `@Refer'ringnovv morevparticularlytoFig. 2, f

the` conductor comprises a.y central conductor core 5, about which are rspirally` i'vrappetil a g n "pluralityV of conducting. strands .6e-'56 i which fpr'eferably v.are so -shapedfas to provide a v smooth eiit'erior surface.v ,posite, conductor is fv'vra'pped a layer of mag-- About this `coni- .neticloading*material-"7 Which'is positioned Vv'vith a spiral lay opposite to that ofthe con-. Vducting strands 6 6.: p j

To 'prevent adhesion between the' conduct- Yingstrands 'and the loading material dured conductor is twisted While subjectedwto the"' `high `t'emperatures` inthe manner disclosed vin- Fig. l. Supply reel 8 uponivvhich thefloaded conductor is Wound as it is re-vk ceived vfrom the serving machine, 'is mounted in the,A forked support 9', rthe rotatable shaft loof vvhichissupported by 'a suitable y l bearing ll'. Upon the end of shaft/l0 there Y l Instead 'of providing an air space betv'veenu the conductor and the tape, as th'ezl'atter is is Ysecurely liXeda gear lZWhicl-i is adapted los ing the subsequentv heat treatment the load-` to mesh 'with' `d.v Similar gear 13, rigidiy Secured to a shaft .upon theopposite. end of Whichis mounted a bevelledgear l5. 4 This ar meshes 'with a bevel pinion '16 mounted on the 'shaft 17 Whijchalso lcarries th'eca'.pl

stan 18 andapulleylfA belt 2O passing L over pulley -l9 and 'asimilar pulley 2l onr shaft 22 lis airangedto rotate "thejreel upon yvvhichY 'theloaded conductor is tof-"loeA 'wound dadi sdbjecnngit ,tothehada trag- 'men'tfv A.

The furnace whichisafsluit:added@Y type* 130 comprises heating elements which are located between the fire clay mui-lie 26 and the iire brick 27 The iron tube 28 has a cop'-l motor 30 upon the shaft of which is a pinion n 31 engaging gear 13 and since capstan l18 and shaft 10 are both positively driven from shaft 14, the reel 8 is rotated positively with respect to the linear travel of the conductor through the furnace. ln practice when the copper conductor is of No. 5 B. and S. gauge, it has been found satisfactory to have the gear ratio suoli that the reel 8 is rotated one complete revolutionl for a conductor travel of four feet. Two sets of pulleys 32 and 33 are provided toguide the conductor into the furnace without causing undue strain. These pulleys may be eliminated by flaring the end of the tube 28. As the loaded conductor passes through the furnace, the direction of rotation of reel 8 is such that the length of conductor extending between reel 8 and capstan 18 is twisted in such a direction that the vcopper strands 6 6 are tightened upon the central core 5 and since the magnetic tape is wound with the opposite direction of lay, this tape is loosened and a slight spacing therefore oc- .curs between the tape and the conducting strands while the conductor is subjected to the heat treatment thus preventing adhesion which might otherwise talle place between the tape and core.

Referring again to Fig. 2, at the right hand portion there is shown somewhat exaggerated the relationship yof the magnetic tape and composite conductor before twisting and at the left hand portion of this figure is shown the condition when the conductor 1s twisted thereby causing the conducting strands to wrap closer to the central core and causing the Vmagnetic tape to be.

loosened slightly.

As a result of the slight spacing caused from the loosening of the tape and the tightening of the conducting strands, the trouble heretofore experienced due to adhesion be-1 tween the magneticy tape and the conductor is largely overcome and the high inductance of the loaded conductor is therefore maintained.

lVhat is claimed is: 1. The method of construct-ing a continuously loaded conductor which comprises wrapping a layerof magnetic lloading mate- 'rial abouta conducting core-,heat treating the loaded conductor to develop high permeability, yandftwistingthe loadedr conductor v while itis undergoing said heattreatment.

2. The method of constructing a loaded Vconductor which comprises wrapping fa, plurality of conducting strands about a central core, wrapping a layer .of magnetic-loading material about the .composite conductor `in van opposite direction, heat treating the loaded conductor to develop highk permeability, and Vtwisting the loaded conductor Vwhile iti is undergoing said heat treatment in the direction to loosen the layer of magnetic material.

3. The methodof constructing a continuously loaded conductor which comprises wrapping a plurality of conducting strands y about a central conducting core, wrapping a layervof loading material about the com posite conductor with a direction of layopposite to that of the conducting strands, heat treating the loaded conductor todevelop high permeability and twisting the loaded conductor while it is being heat treated inea direction to tighten the copper strands about the central core. .Y f w 4. The method of-constructing a continuously loaded conductor v.which comprises wrapping a-plurality of conducting strands;V about a central conducting core, wrapping kay layer of loading material about the composite conductor with a direction of lay opposite to that of the conducting strands, heat treat- `ing -the Vloaded conductor todevelop high;

'the central core and `loosen the loading. ma-

terial about the conducting strands.

5. The method of constructing a continuously loadedy .conductor which comprises wrapping a plurality of conductingstrands about a central conducting core of approximately No. 5 B. and S. gauge, wrapping Ylayer of loading material about the composite conductor with a direction of lay opposite f to that of the conducting strands, heatL treating the` loaded conductor to develophigh permeability, and providing a uniform twist to the conductor as it is being heat treated by rotating the conductor onerevolution for pproximately every four foot-of yconductor travel. 1 Y f 6. rlhe method of constructing a stranded loaded conductor which compriseshelically applying to the conductor a loading material-requiring heat: treatment afterl its lapplication to develop its magnetic characteristics with such a relation betweenv the layy of the strands of the conductor and the lay of the applied loading material that the loading material may be loosened by twisting the loaded conductor, and then twisting the loaded conductor to eEect loosening to such' y' VIValo .Y c

l, l materialandy Eheatiztrfe i. j an extent astred-uce-the strains'v to Whichthe y core, Wrappingaala'yer of magnetic loading'l materialqabout the-#composite conductor in ,*anioppositedirectiomthentwistin theload- -V ed colidiictorto loosenf-thellayer o magnetic c heat treatment 1W ould *subjectv the leading material. 1 f* f 7 .fThefmethod oflconstructiiig.;v r1;);1361

conductor Which-comprises Wrapping' aA plurality tof conducting'strandsjabout a central ating to develop high parmeability.y i

` z.; 8;; Ther methOd- O ou'slyv vloaded --conductor v,which .comprises Wrapping afp'luralityof conducting strands y v -aboutz-a central conducting vcore,'Wrapping a layerfof loading material about thecom'posl fite conductorwith a direction of lay oppo- 1 'site to that ofthe conductingy Strands, lthen twisting the loaded conductor in a direction to tighten the conducting strandsk aboutjthe :9.v The method o central core and heat treating to develop high permeability. n l v l I ff constructing a continuouslylVv loaded conductor Which Vcomprises )Wrappinga Vplurality fof conducting strands about ay central conducting core,`y'vrapping a layer lof loading material about' the ycompositefconductorvwith a direction of lay oppofeo i'site to that of the k'conducting strands,-then vtyvisting the loaded conductor Aina direction ftogtighten the-copper strands about the cen- Wrapping a layer of magnetic loading mate- Yneously subjecting thelloaded vconductor to aheat treatment and to Va mechanicalforce j to develop one of its electrical characteristics.

ftralacorev andloosen the` loading ymaterialabout the conducting strands andlieat treat- Y y v ing theloaded condu v.permeabilityl y 10.The method ous'ly loaded conductor which comprises ctor to ,develop high rial about a conducting core, and-simulta- Y '.115 Ina method of constructingga con-tinuiously. loaded strandedV conductorytlie lstep tof wrapping aV layer -`of 'magnetic material `-aboutastranded"conducting core, followed` V 'ductori to l'develop one offits electricalcliair- Vacteristics and reducing'the diameterfof said e Stranded core by twistingit to preventydele- Y ftrious'eectsof said heat treatment.

Y Adminis# A Inwtness whereof, -the'said Christina-Z.` v VTen Eyck, administratrix, hereunto Sub-y e thisflthday of March,

vscribsi herf nam :,A; 111925C HRIs'riNE z. TEN mfom, ratrz'w of the Estatero f Ten Eyck, Deceased. i

' mamans".

f constructing Va, continuv`ofconstructing a continu-K. 

